Engine Overhaul of D9508 A7 in LG 1750 Crane

Overhaul of the D9508 A7 Engine in the LG 1750 Lattice Boom Mobile Crane

The LG 1750 lattice boom mobile crane is one of the most powerful machines in its class, used for lifting heavy loads at great heights. Equipped with a powerful D9508 A7 combustion engine with an output of 500 kW, it ensures reliable operation in demanding construction and industrial environments. Our service department provides comprehensive repair and regeneration of these power units, focusing on both precision execution and operational safety.

The D9508 A7 engine is a product of a renowned industrial engine manufacturer, characterized by high durability and high efficiency. Its design allows for intensive duty cycles while ensuring low exhaust emissions. The regeneration of such an engine requires experience and professional equipment, including our engine dynamometer (dyno), where every engine undergoes load testing before and after installation in the machine.

Work Stages

Engine Dismantling

The removal of the D9508 A7 engine from the LG 1750 crane is carried out using a crane provided by the customer. The process begins with disconnecting all cables, air pipes, and auxiliary components such as the alternator or starter motor. We secure the cooling system and air intake to avoid damage during the removal of the power unit. The engine is then lifted and transported to our headquarters in Kojszówka, where detailed diagnostics begin.

Component Verification

After the engine arrives at the workshop, we conduct a comprehensive verification of all its components. We check the crank-piston system – crankshaft, connecting rods, pistons, rings, and bearings. Next, the cylinder head is assessed for tightness, valve seat wear, and valve clearances. The fuel system, including the injection pump and injectors, undergoes testing on a test bench. Auxiliary components such as the turbocharger, alternator, and starter are subjected to detailed visual and measurement inspections. If major damage is detected, we take appropriate corrective actions.

Regeneration and Repair

The repair process covers all key engine components. The crank-piston system undergoes crankshaft grinding, replacement of bearings and bushings, and inspection of pistons and rings. The engine head is regenerated by replacing valves and guides, along with a pressure test for tightness. The fuel system involves replacing worn injectors and regenerating the injection pump at a professional facility. Engine accessories, including the turbocharger, starter, and alternator, are checked and repaired according to the manufacturer's requirements. Every engine element is thoroughly cleaned, inspected, and prepared for reassembly.

Engine Assembly

The installation of the D9508 A7 engine in the LG 1750 crane is performed according to the highest service standards. The process begins by positioning the power unit in the engine compartment and precisely securing the mounts and clutch. Next, we install all cables, air piping, cooling system components, and electrical accessories. We pay special attention to the tightness of connections and the exact fit of fuel system components and accessories. After assembly, we conduct initial start-up tests, and the crane operator participates in monitoring the engine's operation, allowing for the detection of any leaks or alignment issues.

Engine Dynamometer Test

After assembly is complete, the D9508 A7 engine undergoes detailed testing on our engine dynamometer. The tests include both light-load operation – 20-30% of nominal power for 16 operating hours – and full-load testing to verify engine performance parameters. The dyno allows us to check compression, oil pressure, crankshaft operation uniformity, and fuel system response under full load. This ensures the customer that the engine is functioning correctly before returning to service in the machine.

Post-Overhaul Engine Maintenance

Every engine after an overhaul is covered by a warranty and service support. We recommend an inspection after the first 50 operating hours, which includes filter replacement and checking mechanical and electrical connections. Subsequent inspections are performed every 250 operating hours or every 3 months, depending on work intensity. Our mobile service travels to the customer, ensuring that repairs and maintenance are carried out efficiently and without crane downtime.

Information about Machines with this Engine

The D9508 A7 engine is installed in LG 1750 lattice boom mobile cranes, which are used in large-scale construction, industrial, and energy projects. Its efficiency and durability make it a preferred choice for operators requiring high reliability and high power.

Summary

A comprehensive overhaul of the D9508 A7 engine in the LG 1750 crane guarantees the restoration of full performance and operational safety of the machine. Professional diagnostics, regeneration of key components, precise assembly, and engine dyno tests ensure the reliable functioning of the power unit. The subsequent inspection after 50 operating hours maintains optimal performance parameters and extends engine life, while our mobile service allows for a quick response to the customer's needs.